System and method for combusting volatile vapors

ABSTRACT

A system for combusting volatile vapors includes: a carburetor having intake valves for receiving fuel from a fuel source, air from an external air intake, and volatile vapors from a vapor source, the carburetor configured to discharge a combustion mixture into a combustion engine; a plurality of sensors configured to generate sensor data based on a respective plurality of physical properties associated with the carburetor and the combustion engine; a programmable controller configured to receive the sensor data as input from each of the plurality of sensors and to control the intake valves to regulate respective ratios of the fuel, air, and the volatile vapors drawn through the carburetor in response to the received sensor data; and a display operatively coupled to the programmable controller to display at least a real-time portion of the sensor data.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 14/275,579 filed May 12, 2014, which claims the benefit ofpriority to U.S. Provisional Patent Application No. 61/822,151, filedMay 10, 2013; the disclosures of which are incorporated herein byreference in their entireties.

FIELD OF THE INVENTION

The field of the present invention relates to systems and processes forcombusting volatile vapors that are remediated or displaced from astorage tank using a combustion engine.

BACKGROUND OF THE INVENTION

Volatile vapors, particularly in the form of hydrocarbons, may bereleased during soil remediation or by being displaced from a storagetank when the storage tank is otherwise filled with a liquid. One optionfor eliminating the recovered or displaced hydrocarbon vapors isincorporate them into a fuel or air stream for intake into an internalcombustion engine, thereby incorporating the volatile vapors into thefuel/air combustion process. Such an internal combustion engine isdisclosed in U.S. Pat. No. 5,424,045, the disclosure of which isincorporated herein by reference in its entirety. While burning volatilein an internal combustion engine can be an effective way of processingthe volatile vapors so that they are not released into the atmospheredirectly, and control systems have been developed for use with suchengines to help them run efficiently, existing control systems generallypresent only rudimentary information to the operator in the form of veryselective raw data about operation of the internal combustion engine.Existing control systems also generally provide only rudimentaryscheduling and information about maintenance of the internal combustionengine. Advancements in such control systems are therefore desirable,especially where data concerning operation and maintenance are so vitalto the uptime and efficient operation of the overall system.

SUMMARY OF THE INVENTION

The present invention is directed toward a system and method forcombusting volatile vapors using a combustion engine, including aprogrammable controller for monitoring and controlling the combustionprocess.

In a first separate aspect of the present invention, a system forcombusting volatile vapors includes a carburetor having a first intakevalve for receiving fuel from a fuel source, a second intake valve forreceiving external air from an external air intake, and a third intakevalve for receiving volatile vapors from a vapor source, the carburetorconfigured to discharge a combustion mixture; a combustion engineoperatively coupled to the carburetor to receive the combustion mixtureinto a combustion chamber; a plurality of sensors configured to generatesensor data based on a respective plurality of physical properties,wherein the plurality of sensors includes a first valve sensoroperatively coupled to the first intake valve, a second valve sensoroperatively coupled to the second intake valve, and a third valve sensoroperatively coupled to the third intake valve, each of the valve sensorsbeing configured to sense a valve position as one of the physicalproperties; a programmable controller configured to receive the sensordata as input from each of the plurality of sensors and to control theintake valves to regulate respective ratios of the fuel, the externalair, and the volatile vapors taken in through the carburetor in responseto the received sensor data; and a display operatively coupled to theprogrammable controller, wherein the programmable controller isconfigured to display at least a real-time portion of the sensor data onthe display as the sensor data is received, the real-time portion of thesensor data including each of the valve positions.

In a second separate aspect of the present invention, a system forcombusting volatile vapors includes: a carburetor having a plurality ofintake valves for receiving fuel from a fuel source, external air froman external air intake, and volatile vapors from a vapor source, thecarburetor configured to discharge a combustion mixture into acombustion chamber of a combustion engine; a plurality of sensorsconfigured to generate sensor data based on a respective plurality ofphysical properties, wherein the plurality of sensors includes aplurality of valve sensors, each valve sensor operatively coupled to oneof the intake valves and configured to sense a valve position as one ofthe physical properties; a programmable controller configured to receivethe sensor data as input from each of the plurality of sensors and tocontrol the intake valves to regulate respective ratios of the fuel, theexternal air, and the volatile vapors taken in through the carburetorand into the combustion engine in response to the received sensor data;and a display operatively coupled to the programmable controller,wherein the programmable controller is configured to display at least areal-time portion of the sensor data on the display as the sensor datais received.

In a third separate aspect of the present invention, a method forcombusting volatile vapors includes: directing the volatile vapors froma vapor source into a combustion engine, wherein a carburetor,comprising a plurality of intake valves for receiving fuel from a fuelsource, external air from an external air intake, and the volatilevapors, discharges a combustion mixture into a combustion chamber of thecombustion engine; sensing a plurality of physical properties using aplurality of sensors configured to generate sensor data, wherein theplurality of sensors includes a plurality of valve sensors, each valvesensor operatively coupled to one of the intake valves to sense a valveposition as one of the physical properties; monitoring the sensor datausing a programmable controller; controlling the one or moreelectronically controlled valves with the programmable controller toregulate respective ratios of the fuel, the external air, and thevolatile vapors drawn through the carburetor and into the combustionengine in response to the monitored sensor data; and displaying at leasta real-time portion of the sensor data on the display as the sensor datais received, the real-time portion of the sensor data including each ofthe valve positions.

Accordingly, an improved system and method for combusting volatilevapors are disclosed. Advantages of the improvements will be apparentfrom the drawings and the description of the preferred embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofthe exemplary embodiments, will be better understood when read inconjunction with the appended drawings. It should be understood,however, that the invention is not limited to the precise arrangementsand instrumentalities shown in the following figures:

FIG. 1 is schematic diagram of a first carburetor having three valves tocontrol air and fuel intakes;

FIG. 2 is a schematic diagram of a second carburetor having two valvesto control air and fuel intakes;

FIG. 3 is a schematic diagram of a programmable controller andassociated sensors for a combustion engine;

FIG. 4 is a schematic diagram of a network incorporating a programmablecontroller for a combustion engine;

FIG. 5 is a diagram showing a hierarchical structure of pages fordisplay by a programmable controller for a combustion engine;

FIG. 6 is a screenshot showing a dashboard page for display by aprogrammable controller for a combustion engine;

FIG. 7 is a screenshot showing an alarms and communications page fordisplay by a programmable controller for a combustion engine;

FIG. 8 is a screenshot showing a data trends page for display by aprogrammable controller for a combustion engine;

FIG. 9 is a screenshot showing a maintenance page for display by aprogrammable controller for a combustion engine;

FIG. 10 is a screenshot showing a service checklist page for display bya programmable controller for a combustion engine;

FIG. 11 is a screenshot showing a parts checklist page for display by aprogrammable controller for a combustion engine;

FIG. 12 is a screenshot showing a well performance page for display by aprogrammable controller for a combustion engine;

FIG. 13 is a screenshot showing a system technician data page fordisplay by a programmable controller for a combustion engine;

FIG. 14 is a screenshot showing an engine data page for display by aprogrammable controller for a combustion engine;

FIG. 15 is a screenshot showing a carburetor data page for display by aprogrammable controller for a combustion engine; and

FIG. 16 is a screenshot showing a well data page for display by aprogrammable controller for a combustion engine.

DETAILED DESCRIPTION OF THE INVENTION

The description of illustrative embodiments according to principles ofthe present invention is intended to be read in connection with theaccompanying drawings, which are to be considered part of the entirewritten description. In the description of embodiments of the inventiondisclosed herein, any reference to direction or orientation is merelyintended for convenience of description and is not intended in any wayto limit the scope of the present invention. Relative terms such as“lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,”“down,” “left,” “right,” “top” and “bottom” as well as derivativesthereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should beconstrued to refer to the orientation as then described or as shown inthe drawing under discussion. These relative terms are for convenienceof description only and do not require that the apparatus be constructedor operated in a particular orientation unless explicitly indicated assuch. Terms such as “attached,” “affixed,” “connected,” “coupled,”“interconnected,” and similar refer to a relationship wherein structuresare secured or attached to one another either directly or indirectlythrough intervening structures, as well as both movable or rigidattachments or relationships, unless expressly described otherwise.Moreover, the features and benefits of the invention are illustrated byreference to the preferred embodiments. Accordingly, the inventionexpressly should not be limited to such preferred embodimentsillustrating some possible non-limiting combinations of features thatmay exist alone or in other combinations of features; the scope of theinvention being defined by the claims appended hereto.

Turning in detail to the drawings, FIG. 1 schematically illustrates asystem 101 for burning volatile vapors, the system 101 including aninternal combustion engine 103, the associated carburetor 105, thesources 107, 109, 111, and the intake valves 113, 115, 117 controllingthe flow from each of the sources 107, 109, 111. Much of the internalcombustion engine 103 operates in a manner well-known to those of skillin the art, wherein the internal combustion engine 103 receives acombustion mixture, which includes fuel, external air, and volatilevapors for the system 101, from the carburetor 105 and ignites thecombustion mixture within a combustion chamber 119.

The intake valves 113, 115, 117, although shown external to thecarburetor 105, may be incorporated into the carburetor 105. The firstintake valve 113 controls flow of fuel from the first source 107, whichis a fuel source, such as a fuel tank. The second intake valve 115controls flow of external air from the second source 109, which is anexternal air source. The third intake valve 117 controls flow ofvolatile vapors from the third source 111, which is a volatile vaporsource, which may be a tank for holding liquid hydrocarbons, or anothersource such as soil remediation. Each of the three intake valves 113,115, 117 may be of different design and construction from the othervalves to accommodate the type of matter being taken into the carburetor105.

The internal combustion engine 103, like most internal combustionengines, includes a fan 121, a radiator 123, both being part of acooling system, an exhaust 121, through which the products of combustionleave the internal combustion chamber 119, and a catalytic converter 123is positioned inline with the exhaust 121.

An internal combustion engine 131 with an alternative intake valveconfiguration is shown in FIG. 2. This alternative configurationincludes a carburetor 133 and two intake valves 135, 137. The firstintake valve 135 controls flow of fuel from the first source 107, whichis a fuel source. The second intake valve 137 controls both the flow ofexternal air from the second source 109, which is an external airsource, and the flow of volatile vapors from the third source 111, whichis a volatile vapor source. The second intake valve 137 combines theexternal air and the volatile vapors into a single stream that is drawninto the carburetor 133. As before, the intake valves 135, 137 are shownexternal to the carburetor 133, may be incorporated into the carburetor105. Other configurations of the intake valves and the sources may alsobe used, such as having a single intake valve for controlling acombination of the fuel and the volatile vapors, among others.

A programmable controller 151 for controlling the combustion engine andmanaging the burning of the volatile vapors is shown in FIG. 3. Theprogrammable controller 151 includes a programmable processor 153, avolatile memory 155, and non-volatile memory 157. The non-volatilememory 157 may be a removable memory, such as a removable hard drive, aremovable SD card, and the like. Both the volatile memory 155 and thenon-volatile memory 157 are used for saving sensor data received by theprogrammable controller 151, for storing programming, and storingoperating parameters associated with operation of the internalcombustion engine 131. The programmable controller 151 is communicablycoupled to a display 159, a geolocation module 161, and a wirelesscommunication module 163. The geolocation module 161 generates ageolocation signal, which identifies the geolocation of the internalcombustion engine (to which the programmable controller is attached),and communicates the geolocation signal to the programmable controller151. The wireless communication module 163 enables the programmablecontroller 151 to communicate wirelessly with other devices directlyand/or over a wide area network. The display 159 may be a touchsensitive display for facilitating interaction with an operator. In someembodiments, the programmable controller 151 may communicate wirelesslywith the display 159. In certain embodiments, the display 159 may beomitted, as the programmable processor 153 may communicate with a remoteprogrammable unit wirelessly using the wireless communication module 163and use a display included with the remote unit for displaying thesensor data.

The programmable controller 151 is also electronically connected tocontrol mechanisms and sensors which enable the programmable controller151, and an operator, to monitor and control operation of the internalcombustion engine for burning the volatile vapors. The various sensorsare positioned in and around the system and configured to generatesensor data based on monitored physical properties associated with thesystem. The sensor data generated by each sensor is communicated to theprogrammable controller, whether in raw form or following processing ofraw sensor data by a sub-controller (such as an analog-to-digitalconverter) to generate a representation of the sensor data. The measuredphysical properties may vary, and the type of sensor employed dependsupon the type of physical property being monitored.

The programmable controller 151 is communicably coupled to three valvesub-controllers 165, 167, 169, each of which is coupled to one of thethree intake valves, respectively, for variably controlling the positionof the respective intake valve by applying a voltage within anoperational range of voltages for each respective valve sub-controller.Additionally, the programmable controller 151 is able to sense thevoltage being applied to each of the valve sub-controllers. Any one ormore of the valve sub-controllers 165, 167, 169 may be incorporated intothe programmable controller 151, or any one or all of the valvesub-controllers 165, 167, 169 may be housed and located separately fromthe programmable controller 151. The programmable controller 151 is alsocommunicably coupled to three valve sensors 171, 173, 175, each of whichis positioned near one of the three intake valves, respectively, so thatthe programmable controller 151 may sense, through the three valvesensors 171, 173, 175, the position of each of the three intake valves.The three valve sensors 171, 173, 175 may communicate an analog signalto the programmable controller 151, or alternatively, the analog signalfrom one or more of the three valve sensors 171, 173, 175 may beconverted into a digital signal by an appropriate analog-to-digitalconverter, with the resulting digital signal being communicated to theprogrammable controller 151.

The programmable controller 151 is communicably coupled to additionalsub-controllers associated with the internal combustion engine, any ofwhich may be incorporated into the programmable controller 151: a hornsub-controller 177; an engine ignition sub-controller 179; a first fuelsolenoid sub-controller 181; a second fuel solenoid sub-controller 183;a starter solenoid sub-controller 185; and an external air manifoldsub-controller 187. These sub-controllers, including the valvesub-controllers 165, 167, 169, enable the programmable controller 151 toexert control over nearly all operational aspects of the internalcombustion engine. Where desired, for a particular sub-controller, theprogrammable controller 151 may apply a variable actuating signal, andthe programmable controller 151 may be configured to sense the voltage(or current) being applied to any of the sub-controllers.

The horn sub-controller 177 enables the programmable controller 151 tohave control over a horn (not shown) associated with the internalcombustion engine, with the horn serving to provide a localized audiblealert signal. The engine ignition sub-controller 179 enables theprogrammable controller 151 to have start and stop control for theinternal combustion engine. The first fuel solenoid sub-controller 181and the second fuel solenoid sub-controller 183 enables the programmablecontroller 151 to actuate two fuel solenoids (not shown), so that theprogrammable controller 151 may shut off the flow of fuel from the fuelsource. The starter solenoid sub-controller 185 enables the programmablecontroller 151 to have actuating control over the starter (not shown)for the internal combustion engine. The combination of the engineignition sub-controller 179 and the starter solenoid sub-controller 185provide the programmable controller with the ability to control thestart-up process for the internal combustion engine. The external airmanifold sub-controller 187 enables the programmable controller 151 tovariably control the rate at which external air is drawn into thesystem, the external air being directed to the air intake valve.

The programmable controller 151 is also communicably coupled tosub-controllers associated with a vapor source, and where the vaporsource is a tank (commonly called a “knockout tank” or “KO tank”, ormore generally, the “well”) these sub-controllers include: a tank purgesub-controller 189; a tank intake valve sub-controller 191; and a tankwater drain sub-controller 193. The tank purge controller 189 enablesthe programmable sub-controller 151 to actuate a tank purge valve (notshown). The tank intake valve sub-controller 191 enables theprogrammable controller 151 to actuate a tank intake valve (not shown).The tank water drain sub-controller 193 enables the programmablecontroller 151 to actuate a tank water drain valve (not shown). Thesesub-controllers enable the programmable controller 151 to exert controlover important operational aspects of a knockout tank. Where desired,for a particular tank sub-controller, the programmable controller 151may apply a variable actuating signal, and the programmable controller151 may be configured to sense the voltage (or current) being applied toany of the tank sub-controllers.

The programmable controller 151 is communicably coupled to and receivesdigital signal input from the following sensors: an emergency stopswitch sensor 201; an engine stop sensor 203; an engine start sensor205; a KO tank water level sensor 207; a KO tank pressure sensor 209; afirst fuel solenoid sensor 211; a second fuel solenoid sensor 213; atachometer 215; and a fuel flow meter 217. The programmable controller151 is communicably coupled to and receives analog signal input from thefollowing sensors: a water temperature sensor 221; an O₂ pre catalyticconverter sensor 223; an O₂ post catalytic converter sensor 225; an oilpressure sensor 227; an external air manifold vacuum sensor 229; a precatalytic converter temperature sensor 231; a post catalytic convertertemperature sensor 233; a system voltage sensor 235; an lower explosivelimit (LEL) sensor 237; a vapor flow meter 239; a well vacuum sensor241; an external air flow meter 245; a door switch sensor 247; and afire system sensor 249. The analog signal from any one or more of theincluded analog sensors may be converted into a digital signal by anappropriate analog-to-digital converter, with the resulting digitalsignal being communicated to the programmable controller 151.

The emergency stop switch sensor 201 enables the programmable controller151 to monitor an emergency stop switch (not shown), so that when theemergency stop switch is actuated by an operator, the programmablecontroller 151 takes all programmed actions for an emergency shut downof the internal combustion engine. The engine stop switch may be ananalog switch, which outputs a digital signal, or a digital switch thatis represented on the display. The engine stop sensor 203 enables theprogrammable controller 151 to monitor an engine stop switch (notshown), so that when the engine stop switch is actuated, theprogrammable controller 151 takes all programmed actions for an orderlyshut down of the internal combustion engine. The engine start sensor 205enables the programmable controller 151 to monitor an engine startswitch (not shown), so that when the engine start switch is actuated,the programmable controller 151 takes all programmed actions for anorderly start up of the internal combustion engine. Either or both ofthe engine stop switch and the engine start switch may be an analogswitch, which outputs a digital signal, or a digital switch which isrepresented on the display.

The KO tank water level sensor 207 enables the programmable controller151 to monitor a water level within the KO tank. The KO tank pressuresensor 209 enables the programmable controller 151 to monitor a pressurewithin the KO tank. The well vacuum sensor 241 enables the programmablecontroller 151 to monitor a vacuum state of the KO tank. The vapor flowmeter 239 enables the programmable controller 151 to monitor a flow ofvolatile vapors from the KO tank.

The first fuel solenoid sensor 211 enables the programmable controller151 to monitor the position of the first fuel solenoid, and the secondfuel solenoid sensor 213 enables the programmable controller 151 tomonitor the position of the second fuel solenoid. The fuel flow meter217 enables the programmable controller 151 to monitor a the flow offuel, such as propane, from the fuel source to the carburetor. Theprogrammable controller 151 may be programmed to convert the signalreceived from the fuel flow meter 217 into cubic feet per minute (CFM).The external air flow meter 245 enables the programmable controller 151to monitor the flow of external air from the external air source (e.g.,the external air manifold) to the carburetor. The programmablecontroller 151 may be programmed to convert the signal received from theexternal air flow meter 217 into CFM.

The tachometer 215 enables the programmable controller 151 to monitorthe rotation rate of the internal combustion engine, thereby measuringthe revolutions per minute (RPM). The oil pressure sensor 227 enablesthe programmable controller 151 to monitor an oil pressure of theinternal combustion engine. The external air manifold vacuum sensor 229enables the programmable controller 151 to monitor the vacuum pressureof the internal external air intake. The water temperature sensor 221enables the programmable controller 151 to monitor the temperature ofwater within the cooling system of the internal combustion engine. TheO₂ pre catalytic converter sensor 223 enables the programmablecontroller 151 to monitor the oxygen level in the exhaust from theinternal combustion engine prior to the exhaust passing through thecatalytic converter, and likewise, the pre catalytic convertertemperature sensor 231 enables the programmable controller 151 tomonitor the temperature of the exhaust from the internal combustionengine prior to the exhaust passing through the catalytic converter.Similarly, the O₂ post catalytic converter sensor 225 enables theprogrammable controller 151 to monitor the oxygen level in the exhaustfrom the internal combustion engine after the exhaust has passed throughthe catalytic converter, and the post catalytic converter temperaturesensor 233 enables the programmable controller 151 to monitor thetemperature of the exhaust from the internal combustion engine after theexhaust has passed through the catalytic converter.

The system voltage sensor 235 enables the programmable controller 151 tomonitor the operating voltage supplied to the programmable controller151. The LEL sensor 237 enables the programmable controller 151 tomonitor the levels combustible vapors (from the KO tank, the fuelsource, or elsewhere) accumulated within the interior of an engineenclosure housing the internal combustion engine. Sufficiently highlevels of such combustible vapors will trigger the programmablecontroller 151 to initiate an appropriate shut down procedure. The doorswitch sensor 247 enables the programmable controller 151 to monitorwhether an access door for the engine enclosure is open or closed. Thefire system sensor 249 enables the programmable controller 151 tomonitor a fire suppression system included within engine enclosure.Activation of the fire suppression system will trigger the programmablecontroller 151 to initiate an appropriate shut down procedure.

The programmable controller 151 is shown as part of a system 251 in anetwork environment in FIG. 4. The network environment may include andoperate over a wide area network, which may be public network such asthe Internet 253. Alternatively, the wide area network may be a privatenetwork or any combination of public and private networks. The networksthemselves may be wired networks, wireless networks, or any combinationof wired and wireless networks. Using the network, the programmablecontroller 151 may communicate with any of a server 255, a remoteprogrammable unit 257, and a remote workstation 259. Login identifiersand passwords may be established for operators to better secure accessto the programmable controller 151 from unwanted network intrusions whenthe network used is at least partially public. The remote programmableunit 257 may be any of a smart phone, a tablet computer, a laptopcomputer, and the like. The remote workstation 259 may be a desktopcomputer or other similar device. In the system 251, only one of eachtype of device is shown for simplicity, while those of skill in the artwill recognize that any number of remote programmable units,workstations, servers, and programmable controllers may be included aspart of the overall system.

The programmable controller 151 may communicate sensor data to any ofthe server 255, the remote programmable unit 257, and the remoteworkstation 259, and the programmable controller 151 may receive controldata from any of the server 255, the remote programmable unit 257, andthe remote workstation 259. The remote programmable unit 257 and theremote workstation 259 may be programmed with the same interactiveprogramming described herein for the programmable controller 151, sothat an operator of the remote programmable unit 257 and the remoteworkstation 259 may interact with the programmable controller 151, alongwith the sensors and sub-controllers with which the programmablecontroller 151 communicates, in the same manner as if the operator wasusing a display, as shown in FIG. 3, to interact with the programmablecontroller 151. When interacting and communicating with the programmablecontroller 151, the remote programmable unit 257 and the remoteworkstation 259 receives sensor data from the programmable controller151 and may send control data to the programmable controller 151. Thecontrol data sent to the programmable controller is the same type ofsettings and parameters data that may be entered by an operator directlyon a display connected to the programmable controller, as shown in FIG.3 and discussed in greater detail below.

As another feature, the programmable controller 151 may communicate withthe server 255 establish a database in which the sensor data may besaved for future reference and analysis. Once the database isestablished by the server 255, according to instructions provided by theprogrammable controller 151, the programmable controller 151communicates sensor data to the server 255, and the server 255 appendsthe received sensor data to the database. The database may take any formor format desired, and may be in the form of an SQL database.

A hierarchical structure of pages 261 for display by the programmablecontroller on the display is shown in FIG. 5. Navigation between thedifferent pages may be achieved by employing a touch-sensitive displayand providing active regions, identified by graphical objects, on thetouch-sensitive display for the operator to move through thehierarchical structure of pages 261. A navigation area may berepresented by a panel on the display which enable the operator totraverse up and down the hierarchy. In addition, a graphical object maybe an active region and leads to a page which enables the operator toinput parameters associated with the feature represented by thegraphical object and/or leads to a page where further information aboutthe feature represented by the graphical object.

When the operator is presented with a page on which parameters may beentered or changed, an appropriate numerical or alphabetical virtual keypad is shown on the display. When an operator wants to make a change toan adjustable parameter, an allowable range for adjusting the parameteris shown on the display. If the operator attempts to adjust theparameter out of the given range, a message indicating that the enteredparameter is out of the allowed range is shown on the display.

The home page 263 of the hierarchical structure of pages 261 is thedefault page that is shown when the programmable controller is initiallyaccessed by an operator. The home page 263 shows the time, date, andtotal run hours for the internal combustion engine. The home page 263may also include additional information, such as a job number, a unitnumber, and a serial number for the internal combustion engine. At leastpart of the home page 263 shows the current operational status bychanging background colors. When the background is a first color, suchas white, it signifies the system is in idle mode and all sensor dataindicates that there are no issues that need to be addressed by theoperator. When the background color is a second color, such as green, itsignifies that the internal combustion engine is in production mode andthere are no issues that need to be addressed by the operator. When thebackground is a third color, such as red, it signifies that an alarm orwarning has been triggered and attention is needed by the operator. Incertain embodiments, an operator may need to enter an identifier and/ora password prior to navigating beyond the home page 263. In addition,operators may be assigned a tech level, with at least two levels beingassignable. The lower tech level, referred to as “tech level 1,” mayhave limited access to certain parts of the programmable controller, andthe higher tech level, referred to as “tech level 2,” has full access tothe programmable controller.

From the home page 263, the operator may navigate to a dashboard page265, an alarms and communications page 267, a maintenance page 269, anda data trends page 271. The data trends page 271 leads to a additionaldata trends pages 273 and to a trends settings page 275. The maintenancepage 269 leads to a tech page 277, a well data page 279, and a servicechecklist page 281. The service checklist page 281 leads to a partschecklist page 283. The well data page 279 leads to a well vacuumsettings page 285, a well valve settings page 287, a catalytic convertertemperature settings page 289, and to a force idle page 291. The techpage 277 leads to a general settings page 293, an engine data page 295,a carburetor data page 297, and a well performance page 299. The generalsettings page 293 leads to an input/output status page 301 and anoverride page 303, and the engine page 295 leads to an engine settingspage 305. The carburetor page 297 leads to a carburetor settings page307, a force idle page 309, and a carburetor calibration page 311.

An exemplary dashboard page 265 is shown in FIG. 6. The dashboard page265 is a summary page which shows real time performance and status dataassociated with the overall system. In an exemplary embodiment, thedashboard page 265 shows: the amount the fuel intake valve for thecarburetor is open 315, as a percentage open; the amount the externalair intake valve for the carburetor is open 317, as a percentage open;the amount the volatile vapor intake valve for the carburetor is open319, as a percentage open; the external air manifold vacuum level 321,the system operating voltage 323, the engine oil pressure 325, theengine water temperature 327, the pre-catalytic converter exhausttemperature 329, the post-catalytic converter exhaust temperature 331,the pre-catalytic converter exhaust O₂ level 333, the post-catalyticconverter exhaust O₂ level 335, the engine RPM 337, and the current dateand time 339. When the data displayed is associated with a maximum orminimum range entered by the operator, the dashboard page 265 will showthe graphical representation of the data in a first color, such asgreen, when the particular real-time sensor data is within the setrange, and it will show the graphical representation of the data in asecond color, such as red, when the particular real-time sensor data isoutside of the set range. Other types of data may be included on thedashboard page 265 based on design choice.

An exemplary alarms and communications page 267 is shown in FIG. 7. Thealarms and communications page 267 shows a list of active faults andalarms 341 in a prominent position near the top of the page, with thealarms listed in chronological order. Alarms remain in the list untilcleared by the operator, with an active region being provided for theoperator to clear an alarm. The alarms and communications page 267 alsoenables passwords to be set for operators, and it provides the operatorwith configuration access for establishing communications with a server,including set-up and management of the database once communications withthe server are established. The alarm and communications page 267 mayalso give the operator an option to download all stored data into anon-volatile memory via a USB port that may be included with theprogrammable controller.

An exemplary data trends page 271 is shown in FIG. 8. The data trendspage 271 shows the real-time and historical sensor data for a selectnumber of the sensors in a graph format. For example, the trends datapage 271 may show the real-time sensor data along with six minutes ofhistorical data. Carburetor trend sensor data is shown in FIG. 8, andthis data includes the position of the three intake valves 343, 345,347, along with the pre- and post-catalytic converter exhaust O₂ levels349 (two lines shown on a single graph) and the pre- and post-catalyticconverter exhaust temperatures 351 (two lines shown on a single graph).Active regions are included so that the operator may switch to trendsassociated with the internal combustion engine and with the well byselecting. Sensor data that may be shown with the engine trend sensordata includes engine oil temperature, engine water temperature, externalair manifold vacuum, and pre- and post-catalytic converter exhaust O₂levels, and pre- and post-catalytic converter exhaust temperatures.Sensor data that may be shown with the well trend sensor data includesthe CFM intake from the well, the parts per million (PPM) ofhydrocarbons in the well intake, the calculated BTU's of thehydrocarbons burned by the internal combustion engine, the well vacuumpressure, and the external air manifold vacuum pressure. Other sensordata may be included in any of the trend pages. The amount of historicalsensor data displayed may be set by the user, as is the amount ofhistorical data stored by the programmable controller. Both theseparameters may be set in the trends settings page 275 by the operatorentering the desired values for each parameter.

The trends data can be valuable when performing maintenance on thesystem. For example, the operator may be able to tell from the trendsdata if the engine performance has changed gradually over time,resulting in an alarm being triggered from the sensor data associatedwith one of the sensors going beyond the maximum or minimum presetvalues, or if the sensor data has become erratic, thereby exceeding oneof the preset values and being indicative of a failing sensor. In eachinstance, the action taken by the operator to perform maintenance willbe significantly different. In the former case, the operator may need toperform an overall service of the internal combustion engine, and in thelatter case, the operator may need to do nothing more than replace thefailing sensor.

An exemplary maintenance page 269 is shown in FIG. 9. The maintenancepage 269 shows two different countdown timers 357, 359, with the firstcountdown timer 357 counting down the time until the next 100-hourgeneral service of the internal combustion engine, and the secondcountdown timer 359 counting down the time until the next 1000-hourgeneral service of the internal combustion engine. Each countdown timer357, 359 shows remaining time until the next service interval and theappropriate reset and delay options. A reset button 361, 363 and a delaybutton 365, 367 are included for each countdown timer 357, 359. Thereset buttons 361, 363 reset the respective timers, while the delaybuttons 365, 367 serve to postpone the alarm associated with eachcountdown timer 357, 359. Preferably, each countdown timer 357, 359 mayonly be postponed for a limited time before a fault is entered that canonly be cleared by performing the designated maintenance. The totaloperating time of the internal combustion engine 369 is also displayedand tracked, and a button is provided to reset the total operating time371.

The programmable controller also tracks certain events associated withmaintenance of the system. The tracked items may include: when theregular service countdown timer is reset; when the regular service faultis postponed; when the complete service countdown timer is reset; whenthe complete service fault is postponed; when the total time on the unitis reset; when the regular service countdown timer expires; and when thecomplete service countdown timer expires.

An exemplary service checklist page 281 is shown in FIG. 10. This pageenables an operator to check a service item to indicate that the servicehas been performed. When an item changes status from un-checked tochecked (i.e., not yet serviced to serviced), the programmablecontroller tracks the event when the operator leaves the servicechecklist page 281. An exemplary parts checklist page 283 is shown inFIG. 11. This page enables an operator to check a parts item to indicatethat the part has been serviced (e.g., the required maintenance on thatpart has been performed, or the part has been replaced). When an itemchanges status from un-checked to checked (i.e., not yet serviced toserviced), the programmable controller tracks the event when theoperator leaves the service checklist page 281 (not when the operatorleaves the parts checklist page 283). The parts checklist page may applyto individual parts of the internal combustion engine, or it may applyto sub-systems of the engine. The types of service items and parts itemsincluded on each of the service checklist page 281 and the partschecklist page 283 may vary based upon design choice.

An exemplary well performance page 299 is shown in FIG. 12. The wellperformance page 299 serves as a quick reference to data associated withthe well or data that is associated with the burn rate of the volatilevapors from the well. As shown, the well performance page 299 includessimple graphs showing the calculated BTUs per hour 381 generated byburning the volatile vapors from the well; the parts per million ofhydrocarbons 383 included in the volatile vapors from the well; the CFMof volatile vapors 385 from the well; the CFM of fuel from the fuelsource 387; and the external air manifold vacuum level 389. Other datamay be included as desired on the well performance page 299.

An exemplary tech data page 277 is shown in FIG. 13. The tech data page277 gives real time readings of the fuel system, engine, and wellconditions. In addition, there may be two versions of the tech data page277, with both having the same appearance, and the difference being thaton one tech page the operator is limited in the changes that can be madeto the parameters shown, and in the other tech page the operator maychange the parameters without limit. The difference is determined bytech level assigned to the operator logging into the programmablecontroller. Tech level 1 operators may be limited to changing aperformance parameter by no more than 25% of that value for theperformance parameter as set by a tech level 2 operator. Otherrestrictions may be applied to tech level 1 operators, as desired.

The tech data page 277 includes the following real-time sensor data andcolor indicators showing whether the sensor data displayed is within adesired operating range: the status of the first fuel solenoid 391 (offor on); the status of the second fuel solenoid 393 (off or on); the fuelflow rate 395; the external air manifold vacuum 397; the external airflow rate 399; the volatile vapor flow rate 401 from the well; the wellvacuum 403; the KO tank purge valve status 405; the KO tank water drainvalve status 407; the pre- and post-catalytic converter exhaust O₂levels 409, 411; the pre- and post-catalytic converter exhausttemperatures 413, 415; the engine start switch status 417; the enginestop switch status 419; the engine RPM 420; the engine oil pressure 421;the engine fan status 423; the engine water temperature 425; the LELpercentage 427 in the engine enclosure; the engine enclosure door status429; the fire suppression system status 431; the emergency engine stopstatus 433; and the system voltage 435. For certain of the sensor datadisplayed, it is also desirable to include a third color indicator tovisually show when the sensor data has passed a predetermined warninglimit, this warning limit being outside of the desired operating range.The sensors for which it may be desirable to have this third colorindicator include at least all engine exhaust sensors, the well flowrate and well vacuum sensors, all external air-related sensors, and allfuel-related sensors.

Each graphical object of the various sensor data shown on the tech datapage 277 is an active region and leads to a page which enables theoperator to input parameters associated each respective sensor. Theparameters may serve to establish a predetermined limit, which may be anupper, a lower, or both, for the associated sensor. In the event thatthe predetermined limit is reached during operation, the programmablecontroller will take a predetermined action, also identified by theoperator, which may include one or more of setting a fault alert,communicating the alert with a server, a remote unit, and/or aworkstation, sounding an audible alert with the horn, and shutting downoperation of the internal combustion engine, among other possibleactions.

An exemplary engine data page 295 is shown in FIG. 14. The engine datapage 295 shows the current engine status, and it includes the followingreal-time sensor data and color indicators showing whether the sensordata displayed is within a desired operating range: the pre- andpost-catalytic converter exhaust O₂ levels 409, 411; the pre- andpost-catalytic converter exhaust temperatures 413, 415; the enginestarter status 441; the engine RPM 420; the engine oil pressure 421; theengine fan status 423; the engine water temperature 425; and the systemvoltage 435. For certain of the sensor data displayed, it is alsodesirable to include a third color indicator to visually show when thesensor data has passed a predetermined warning limit, this warning limitbeing outside of the desired operating range. The sensors for which itmay be desirable to have this third color indicator include all engineexhaust sensors, the engine oil pressure, the engine water temperature,and the system voltage.

The settings page associated with the engine may be a single page or thesettings options may be divided across several pages. The settingsoptions associated with the engine include production parameters, engineparameters, engine idle parameters, and startup and shutdown parameters.The production parameters may include the minimum exhaust temperaturespre- and post-catalytic converter during operation, along with a minimumoperating engine temperature and the desired operating RPM for theinternal combustion engine. The engine parameters may include a maximumdifference between the pre- and post-catalytic converter O₂ levels, theminimum oil pressure, the engine temperature at which the fan isactuated on, the minimum RPM for a standard shutdown procedure, theengine temperature warning level, and an O₂ control loop setpoint. Theidle parameters may include an idle mode threshold, an idle modeduration timer, and an idle mode RPM for the internal combustion engine.The startup and shutdown parameters may include an engine stop delaytimer, a set number of attempts for an automatic restart, a time delaybetween a shutdown and a restart, the LEL shutdown level, and a LELdelay timer to set the restart time delay after an LEL shutdown event.

An exemplary carburetor data page 297 is shown in FIG. 15. Thecarburetor data page 297 shows the current positions of the three intakevalves 437, 439, 441 as well as the current carburetor status. Thecarburetor data page 297 includes the following real-time sensor dataand color indicators showing whether the sensor data displayed is withina desired operating range: the status of the first fuel solenoid 391(off or on); the status of the second fuel solenoid 393 (off or on); thefuel flow rate 395; the external air manifold vacuum 397; the externalair flow rate 399; the volatile vapor flow rate 401 from the well; and ageneral status indicator for the well 443 showing if the well is in a“good” condition or if sensor data associated with the well is out ofrange. For certain of the sensor data displayed, it is also desirable toinclude a third color indicator to visually show when the sensor datahas passed a predetermined warning limit, this warning limit beingoutside of the desired operating range. The sensors for which it may bedesirable to have this third color indicator on the carburetor data page297 include the flow rate of the fuel, external air, and volatile vaporsand the external air manifold vacuum pressure.

The settings page associated with the carburetor may be a single page orthe settings options may be divided across several pages. The settingsoptions associated with the carburetor include start variable settingsand maximum/minimum valve settings. In addition, the carburetor page 297may link the force idle page, discussed above, and a calibration pagefor the intake valves. The start variable settings page may includeinitial settings for the fuel intake valve and the air intake valve atstartup of the internal combustion engine. These initial valve settingsmay be expressed as a percentage open, with 0% being fully closed and100% being fully open. The maximum/minimum valve settings page enablesthe operator to set the minimum and maximum valve opening parameters foreach of the fuel intake valve, the external air intake valve, and thevolatile vapor intake valve.

On the valve calibration page, the operator may manually actuate any ofthe intake valves to a designated opening, again expressed as apercentage open, and the programmable controller displays both thesensor data from the valve sensor associated with the manually actuatedvalve, as a percentage open, and the voltage applied to the valve toachieve the manually entered parameter. The operator may then comparethe valve operation with known technical specifications for the valve todetermine if the valve is in need of cleaning or being replaced. Inalternative embodiments, the same procedure may be performed on othervalves or solenoids incorporated into the system.

An exemplary well data page 279 is shown in FIG. 16. The well data page279 includes the following real-time sensor data and color indicatorsshowing whether the sensor data displayed is within a desired operatingrange: the volatile vapor flow rate 401 from the well; the well vacuum403; the KO tank purge valve status 405; the KO tank water drain valvestatus 407; the well intake sensor 445; the well purge sensor 447; andthe well water drain sensor 449. The well data page 299 also includesgraphical buttons 451, 453 as active regions for the operator to actuatethe KO tank purge valve and the tank water drain valve.

From the well data page 279, the operator may navigate to the wellvacuum settings page 285, the well valve settings page 287, thecatalytic converter temperature settings page 289, and to the force idlepage 291. On the well vacuum settings page 285, the minimum and maximumwell vacuum parameters may be set by the operator. On the well valvesettings page, the operator may adjust the gain/time for opening up thewell intake valve following startup of the internal combustion engine.On the catalytic converter temperature settings page 289, the operatormay set the pre- and post-catalytic converter exhaust temperaturewarning parameter and the well lean temperature parameter.

Although not depicted, the general settings page 293 is a page on whichthe operator may enter general settings and parameters for the system.These parameters may include the job number, the unit number, and theserial number for the internal combustion engine. The input/outputstatus page 301 shows the current condition of all the digital inputs,digital outputs, and analog inputs for the programmable controller,along with the real-time sensor data associated with each input. Theoverride page 303 enables the operator to override any of the digitalinputs, digital outputs, and analog inputs for the programmablecontroller. Manually overriding one of the inputs or outputs can behelpful for troubleshooting a bad wire, sensor, solenoid, and switch. Incertain embodiments, the override page 303 is only available to anoperator who is a tech level 2.

While the invention has been described with respect to specific examplesincluding presently preferred modes of carrying out the invention, thoseskilled in the art will appreciate that there are numerous variationsand permutations of the above described systems and techniques. It is tobe understood that other embodiments may be utilized and structural andfunctional modifications may be made without departing from the scope ofthe present invention. Thus, the spirit and scope of the inventionshould be construed broadly as set forth in the appended claims.

What is claimed is:
 1. A system for combusting volatile vapors, thesystem comprising: a carburetor having a first intake valve forreceiving fuel from a fuel source, a second intake valve for receivingexternal air from an external air intake, and a third intake valve forreceiving volatile vapors from a vapor source, the carburetor configuredto discharge a combustion mixture; a combustion engine operativelycoupled to the carburetor to receive the combustion mixture into acombustion chamber; a plurality of sensors configured to generate sensordata based on a respective plurality of physical properties, wherein theplurality of sensors includes a first valve sensor operatively coupledto the first intake valve, a second valve sensor operatively coupled tothe second intake valve, and a third valve sensor operatively coupled tothe third intake valve, each of the valve sensors being configured tosense a valve position as one of the physical properties; the sensorsincluding one or more vapor pressure sensors, each of the one or morevapor pressure sensors operable to sense a vapor source pressure orvacuum as one of the physical properties; a programmable controllerconfigured to receive the sensor data as input from each of theplurality of sensors and to control the intake valves to regulaterespective ratios of the fuel, the external air, and the volatile vaporstaken in through the carburetor in response to the received sensor data;and a display operatively coupled to the programmable controller,wherein the programmable controller is configured to display at least areal-time portion of the sensor data on the display as the sensor datais received, the real-time portion of the sensor data including each ofthe valve positions; wherein the programmable controller is furtherconfigured to modify the valve positions of each of the intake valvesbased on the sensed vapor source pressure or vacuum and within a rangeof minimum to maximum valve opening settings for each intake valveprogrammed into the programmable controller.
 2. The system of claim 1,further comprising a wireless communication module communicably coupledto the programmable controller and configured to enable wirelesscommunication between the programmable controller and a wide areanetwork.
 3. The system of claim 2, wherein the programmable controllerwirelessly communicates with the display.
 4. The system of claim 2,further comprising a remote programmable unit configured to communicatewith the programmable controller via the wide area network.
 5. Thesystem of claim 1, wherein the programmable controller is furtherconfigured to color code individual parts of the real-time portion ofthe sensor data on the display in accordance with a comparison of eachindividual part with one of a predefined value or a predefined range. 6.The system of claim 1, wherein the programmable controller is furtherconfigured to receive control data and actuate one or more of the intakevalves to a position defined by the control data in response toreceiving the control data.
 7. The system of claim 1, wherein theprogrammable controller is further configured to receive control datawhich establishes a predetermined limit for sensor data received fromone of the plurality of sensors.
 8. The system of claim 7, wherein theprogrammable controller is further configured to take a predeterminedaction when the predetermined limit is reached by the sensor datareceived from one of the plurality of sensors.
 9. The system of claim 7,wherein the programmable controller is further configured to communicatean alert to at least one of the display and a remote unit when thepredetermined limit is reached by the sensor data received from one ofthe plurality of sensors.
 10. The system of claim 1, wherein theprogrammable controller is further configured to display historicalsensor data on the display for a predetermined time period prior to thesensor data being received.
 11. The system of claim 1, wherein theprogrammable controller is further configured to monitor a voltageapplied to one of the intake valves and to display the monitored voltageon the display concurrently with the sensor data from the one of theintake valves.
 12. The system of claim 1, wherein the programmablecontroller is further configured to monitor a maintenance schedule forthe combustion engine.
 13. The system of claim 12, wherein themaintenance schedule includes separate scheduling for maintenance of aplurality of subsystems of the combustion engine.
 14. The system ofclaim 1, wherein the plurality of sensors further includes one or moreof: an exhaust sensor configured to sense a chemical component in anexhaust from the combustion engine as one of the physical properties; arotation rate meter configured to sense the revolutions per minute (RPM)of the combustion engine as one of the physical properties; a vapor flowmeter operatively coupled between the carburetor and the vapor sourceand configured to sense a flow rate of the volatile vapors flowing tothe carburetor from the vapor source as one of the physical properties;a fuel flow meter operatively coupled between the carburetor and thefuel source and configured to sense a flow rate of the volatile vaporsflowing to the carburetor from the fuel source as one of the physicalproperties; an oxygen sensor operatively coupled between the carburetorand the external air intake and configured to sense oxygen levels in theexternal air flowing into the carburetor from the external air intake asone of the physical properties; one or more temperature sensors, each ofthe one or more temperature sensors positioned to sense an operatingtemperature of the combustion engine as one of the physical properties;and one or more pressure sensors, each of the one or more pressuresensors being positioned to sense one of an engine oil pressure as oneof the physical properties.
 15. A system for combusting volatile vapors,the system comprising: a carburetor having a plurality of intake valvesfor receiving fuel from a fuel source, external air from an external airintake, and volatile vapors from a vapor source, the carburetorconfigured to discharge a combustion mixture into a combustion chamberof a combustion engine; a plurality of sensors configured to generatesensor data based on a respective plurality of physical properties,wherein the plurality of sensors includes a plurality of valve sensors,each valve sensor operatively coupled to one of the intake valves andconfigured to sense a valve position as one of the physical properties;the sensors including one or more vapor pressure sensors, each of theone or more vapor pressure sensors operable to sense a vapor sourcepressure or vacuum as one of the physical properties; a programmablecontroller configured to receive the sensor data as input from each ofthe plurality of sensors and to control the intake valves to regulaterespective ratios of the fuel, the external air, and the volatile vaporstaken in through the carburetor and into the combustion engine inresponse to the received sensor data; and a display operatively coupledto the programmable controller, wherein the programmable controller isconfigured to display at least a real-time portion of the sensor data onthe display as the sensor data is received; wherein the programmablecontroller is further configured to modify the valve positions of eachof the intake valves based on the sensed vapor source pressure or vacuumand within a range of minimum to maximum valve opening settings for eachintake valve programmed into the programmable controller.
 16. The systemof claim 15, wherein the plurality of intake valves includes a firstintake valve configured to control flow of the fuel and a second intakevalve configured to control flow of the external air and the volatilevapors, and the plurality of sensors includes a first valve sensoroperatively coupled to the first intake valve and a second valve sensoroperatively coupled to the second intake valve, each of the valvesensors being configured to sense a valve position as one of thephysical properties.
 17. The system of claim 15, wherein the pluralityof intake valves includes a first intake valve configured to controlflow of the fuel, a second intake valve configured to control flow ofthe external air, and a third intake valve configured to control flow ofthe volatile vapors, and the plurality of sensors includes a first valvesensor operatively coupled to the first intake valve, a second valvesensor operatively coupled to the second intake valve, and a third valvesensor operatively coupled to the third intake valve, each of the valvesensors being configured to sense a valve position as one of thephysical properties.
 18. The system of claim 15, further comprising awireless communication module communicably coupled to the programmablecontroller and configured to enable wireless communication between theprogrammable controller and a wide area network.
 19. The system of claim18, wherein the programmable controller wirelessly communicates with thedisplay.
 20. The system of claim 18, further comprising a remoteprogrammable unit configured to communicate with the programmablecontroller via the wide area network.